Storage system with stacking totes

ABSTRACT

A system for holding items includes a base tier including two or more totes and one or more higher tiers stacked on the base tier. Each of the higher tiers includes one or more totes stacked on a tote of a lower tier. Totes in of the tiers are laterally cross coupled to one another. The totes include lateral openings that allow removal of items through the lateral opening while the totes are stacked in place

This application is a divisional of U.S. patent application Ser. No.12/981,000, filed Dec. 29, 2010, now U.S. Pat. No. 8,960,469, which ishereby incorporated by reference in its entirety.

BACKGROUND

Electronic marketplaces (e.g., Internet- or web-based marketplaces) havebecome legitimate alternatives to traditional “brick and mortar” retailstores. For instance, consumers may visit a merchant's website to viewand/or purchase goods and services offered for sale by the merchant(and/or third party merchants). In many cases, consumers appreciate theconvenience and simplicity of the shopping experience provided byelectronic marketplaces. For example, a consumer may quickly browse anelectronic catalog (e.g., via a web browser) and select one or moreitems from the catalog for purchase. Such items may be shipped directlyto the consumer thereby relieving the consumer of the inconvenience oftraveling to a physical store.

Some electronic marketplaces include large electronic catalogs of itemsoffered for sale. Distributors that operate such marketplaces mayprocess inventory of items in one or more facilities (e.g., warehouses,distributions centers, etc.). Some product sellers have facilities inonly a relatively small number of locations. Shipping from the smallnumber to myriad domestic and foreign locations of customers requiresthat many items be shipped long distances.

Some product sellers experience large seasonal fluctuations. Forexample, some retail merchants experience very high product demandduring holiday seasons. These seasonal fluctuations cause spikes infacilities requirements. To meet the facilities requirements duringthese spikes, sellers may create and stock temporary facilities, such asa holiday fulfillment center. Such temporary facilities may, however, beexpensive to equip and maintain. For example, a large amount of shelvingmay need to be constructed for a temporary fulfillment center.Conventional shelving may be capital intensive and labor intensive toconstruct, and may require significant planning, permitting,inspections, and certifications. Moreover, even where such temporaryfacilities can be made available, the facilities may not be in theoptimal locations relative to the customer base.

Even after seasonal requirements have subsided for temporary facilities,temporary facilities and the associated equipment may consume asubstantial amount of resources.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one embodiment of a system for holding items thatinclude cross coupled totes.

FIG. 2 is a top view illustrating one embodiment of a tote that can beused as modular elements for a shelving system.

FIG. 3 is a bottom view illustrating a corner of a tote having a sideinterlock socket and a split back interlock tail.

FIG. 4 is a bottom view illustrating a corner of a tote having a sideinterlock tail and a split front interlock socket.

FIG. 5 illustrates one embodiment of a system having totes that arecross coupled in the front-to-back direction and in the side-to-sidedirection.

FIG. 6 is a bottom view illustrating a side interlock connection betweentwo adjoining totes.

FIG. 7 is a bottom view illustrating a corner interlock connection offour totes.

FIG. 8 illustrates an embodiment of one tier of a tote system includinginterlocking totes and removable panels.

FIG. 9 illustrates one embodiment of a removable panel for a tote.

FIG. 10 illustrates one embodiment of a handle for a tote.

FIG. 11 illustrates an embodiment of a tote system including a divider.

FIG. 12 illustrates a tote including stop elements for nesting totes.

FIG. 13 is a cross sectional view of two totes in a nested relationship.

FIGS. 14 and 15 are bottom views illustrating elements of a blinddovetail connection.

FIG. 16 illustrates a U-shaped coupler for cross coupling totes.

FIG. 17 illustrates a device for cross coupling four totes at a commonintersection of the totes.

FIG. 18 illustrates one embodiment of a snap-in connection betweenstacked totes.

FIG. 19 illustrates operation of a materials handling facility thatincludes one or more inventory storage locations.

FIG. 20 illustrates one embodiment of holding items in stacked totes.

FIG. 21 illustrates one embodiment of making a shelving system withstacked totes.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and will herein be described in detail. Itshould be understood, however, that the drawings and detaileddescription thereto are not intended to limit the invention to theparticular form disclosed, but on the contrary, the intention is tocover all modifications, equivalents and alternatives falling within thespirit and scope of the present invention as defined by the appendedclaims. The headings used herein are for organizational purposes onlyand are not meant to be used to limit the scope of the description orthe claims. As used throughout this application, the word “may” is usedin a permissive sense (i.e., meaning having the potential to), ratherthan the mandatory sense (i.e., meaning must). Similarly, the words“include,” “including,” and “includes” mean including, but not limitedto.

DETAILED DESCRIPTION OF EMBODIMENTS

Various embodiments of systems and methods for storing items in totesare described. According to one embodiment, a system for holding itemsincludes a base tier including two or more totes and one or more highertiers stacked on the base tier. Each of the higher tiers includes one ormore totes stacked on a tote of a lower tier. Totes in of the tiers arelaterally cross coupled to one another. The totes include lateralopenings that allow removal of items through the lateral opening whilethe totes are stacked in place.

According to one embodiment, a tote for holding items includes one ormore item-holding portions, one or more coupling portions, and one ormore lateral openings. The coupling portions can laterally couple thetote with at least one other tote. The lateral openings allow removal ofitems from the tote through the lateral openings.

According to one embodiment, a method of holding items includesproviding one or more items in each of two or more totes. The totesinclude one or more lateral openings. At least two of the totes arelaterally cross with one another to form a base tier of totes. Totes arestacked on the base tier totes to form at least one higher tier oftotes. The totes are stacked such that the items in the totes areremovable through at least one of the lateral openings.

According to one embodiment, a method of making a shelving system forstoring items includes cross coupling two or totes to form a base tierof totes. The totes include one or more lateral openings. Totes arestacked on the totes in the base tier to form at least one higher tierof totes. The totes are stacked such items can be placed into the totesthrough the lateral openings.

As used herein, “coupled to” includes a direct connection or an indirectconnection. Elements may be coupled to one another in any of variousmanners, including a fixed connection, pivoting connection, slidingconnections, or combinations thereof.

As used herein, “cross coupled” means items are coupled to mutuallyinhibit separation of the items from one another.

As used herein, “interlock” includes a combination of elements, orportions thereof, that cooperate to inhibit separation of two or morecomponent or elements from one another. In some embodiments, interlockselements are integral to the parts being held together (for example,dovetails, grooves, lips, or protrusions). In other embodiments,interlock elements are separate parts (for example, coupling links,pins, or clips). Interlocking elements may connect in a press fit or aclearance fit. In certain embodiments, interlocking elements may snaptogether.

As used herein, “lateral” or “laterally” includes in a lateral directionor a generally horizontal direction. A lateral opening in a tote may be,for example, in the front side, back side, left side, or right side ofthe tote.

As used herein, a “pin” includes any element that can be positioned toconstrain or hold another element in a desired position or orientation.Suitable pins may include straight pins, pegs, threaded bolts,unthreaded bolts, bars, plates, hooks, rods, or screws.

As used herein, “shelving” includes any system, element, or combinationthereof that has one or more shelves, platforms, or other surfaces forholding items.

As used herein, a “space” means a space, area or volume.

As used herein, “tier” means a row or layer of one or more objects. Atier may be part of an arrangement or assembly of objects. Objects inone tier may be above or below items in one or more other tiers ofobjects within an arrangement. For example, a stack of totes may includea bottom tier and one or more higher tiers above the bottom tier.

As used herein, “tote” means a bin, crate, box, or other container inwhich or on which one or more items can be placed. A tote may be open onor more of its sides. In various embodiments, a tote can be used forstorage, transportation, display, or environmental protection. A totemay be any shape or size.

In some embodiments, two or more totes are connected with one another tocreate shelving for holding items. FIG. 1 illustrates one embodiment ofa system for holding items that include cross coupled totes. System 100includes totes 102 and removable walls 104. Items such as books, CDs, orDVDs may be held in each of totes 102. Totes 102 are stacked on oneanother to form columns and arranged next to one another to form rows.Totes 102 are arranged in tiers 106A, 106B, and 106C.

Removable walls 104 physically separate contents in the front columns oftotes 102 from the contents in the back columns of totes 102. Each oftotes 102 includes front opening 110 and back opening 112. Frontopenings 110 and back openings 112 may allow contents in totes 102 to beremoved from the totes. For example, in the arrangement shown in FIG. 1,front openings 110 may allow contents to be removed from the front oftotes 102 on the front side of system 100. Back openings 112 may allowcontents to be removed through the back of totes 102 on the back side ofsystem 100.

In the embodiment illustrated in FIG. 1, system 100 is two totes wide(side to side) by two totes deep (front to back) by three totes high.Nevertheless, a shelf system may, in various embodiments, be any numberof totes wide, deep, or high. In one embodiment, a shelf system is eighttotes wide, two totes deep, and seven totes high. The width of a totesystem may be, in one embodiment, about 16 feet.

Within each of tiers 106A, 106B, and 106C, totes 102 may be crosscoupled front-to-back and side-to-side. For example, in tier 106C shownin FIG. 1, totes 102 in front columns 114 couple with the adjacent totes102 in rear columns 116 at interlocks 118, and totes 102 on left columns120 couple with totes 102 on right columns 122 at interlocks 124.

Although in the embodiment shown in FIG. 1, totes in a system arecoupled in two directions (front-to-back and side-to-side), in certainembodiments, totes in a system may be cross coupled in only onedirection (for example, side-to-side only, or front-to-back only).

Totes may be used to store any items. Examples of items that can bestored in a tote include books, CDs, DVDs, software media, jewelry,apparel (for example, men's dress shirts), shoes, hardware, officesupplies, or household items.

FIG. 2 is a top view illustrating one embodiment of a tote that can beused as a modular element for a shelving system. Tote 140 includesbottom panel 142, front panel 144, back panel 146, and side panels 148Aand 148B. Side panels 148A and 148B include handles 150. Front panel 144includes front opening 152. Back panel 146 includes back opening 154.

Bottom panel 142 includes corrugations 155. Corrugations 155 mayincrease the load bearing capacity of tote 140 and/or increase rigidityof bottom panel 142 when items are placed in tote 140.

In some embodiments, a tote includes cross coupling portions. The crosscoupling portions can be used, for example, to couple with other toteswithin a tier of a storage system. In some embodiments, couplingportions are used to interlock one tote with another. In FIG. 2, forexample, tote 140 includes dovetail interlock elements. Side panel 148Aincludes side interlock sockets 160. Side panel 148B includes sideinterlock tails 162. Front panel 144 includes front interlock socket166. Front interlock socket 166 is split by front opening 152. Backpanel 146 includes back interlock tail 168. Back interlock tail 168 issplit by back opening 154.

FIG. 3 is a bottom view illustrating a corner of a tote having a sideinterlock socket and a split back interlock tail. Tote 140 includes sideinterlock socket 160 and back interlock tail 168.

FIG. 4 is a bottom view illustrating a corner of a tote having a sideinterlock tail and a split front interlock socket. Tote 140 includesside interlock tail 162 and front interlock socket 166.

FIG. 5 illustrates one embodiment of a system having totes that arecross coupled in the front-to-back direction and in the side-to-sidedirection. Side interlock sockets 160 of totes 140 may interlock withinterlock tails of an adjacent tote to cross couple side panel 148A oftotes 140 with the side of the adjacent tote. Side interlock tails 162of totes 140 may interlock with side interlock sockets on an adjacenttote to cross couple side panel 148B of totes 140 with the adjacenttote.

Front interlock socket 166 of totes 140 may interlock with a backinterlock tail on an adjacent tote to couple front panel 144 of tote 140with the back of the adjacent tote. Back interlock tail 168 of totes 140may interlock with a front interlock socket on an adjacent tote tocouple back panel 144 of tote 140 with the front of the adjacent tote.

FIG. 6 is a bottom view illustrating a side interlock connection betweentwo adjoining totes. Side interlock tail 162 and side interlock socket160 interlock to couple side panel 148A of one of totes 140 with sidepanel 148B of another one of totes 140.

FIG. 7 is a bottom view illustrating a corner interlock connection offour totes. Front interlock tail 168 of one of totes 140 interlocks withback interlock tail 166 of another one of totes 140 to couple the totesfront-to-back.

In some embodiments, totes are stackable such that one tote can beplaced on top of another in a manner that maintains all or most of thestorage capacity within each tote. In the embodiment shown in FIGS. 2and 5, side panel 148A of tote 140 includes central shelf 180. Sidepanel 148B of tote 140 includes corner shelves 182. One of cornershelves 182 is provided in each corner on side panel 148B. Central shelf180 includes central alignment posts 184. Corner shelves 182 includecorner alignment posts 186.

Tote 140 includes central pads 190 adjoining side panel 148B and cornerpads 192 adjoining side panel 148A. As shown in FIGS. 3, 4, and 6,central pads 190 include central alignment sockets 194. Corner pads 192include corner alignment sockets 196.

Totes 140 may be stacked in an alternating orientation, such that eachtote is rotated in a horizontal plane 180 degrees relative to the toteit is stacked upon. Thus, when totes 140 are stacked on top of another,central pad 190 on side panel 148B of each of totes 140 may rest oncentral shelf 180 on side panel 148A of the tote immediately below. Eachof corner pads 192 on side panel 148A may rest on one of corner shelves182 on side panel 148B of the tote immediately below. With eachadditional tier, the orientation of the totes may be reversed such that,for any given tote, side panel 148A is resting on side panel 148B of thetote below and side panel 148B is resting on side panel 148A of the totebelow.

When totes 140 are stacked on top of another, each of corner alignmentsockets 196 on side panel 148B of one tier of totes 140 may align withand receive one of corner alignment posts 186 on side panel 148A of thetier of totes 140 immediately below it. Each of central alignmentsockets 194 on side panel 148A of the lower tier of totes 140 may alignwith and receive one of central alignment posts 184 on side panel 148Bof the tier of totes 140 immediately below it. Engagement of alignmentsockets on alignment posts of a lower tier of totes may maintain thetotes in a stacked relationship with one another.

In some embodiments, a tote includes one or more removable panels.Removable panels may provide protection for, and/or retain, items in atote. Removable panels may provide lateral access to the contents of atote. FIG. 8 illustrates an embodiment of one tier of a tote systemincluding interlocking totes and removable panels. FIG. 9 illustratesone embodiment of a removable panel for a tote. In some embodiments, aremovable panel may be used, for example, to fill front opening 152 orback opening 154 of tote 140 shown in FIG. 8. Removable panel 200includes wall 202, rails 204, pins 206, and latching tabs 208. Wall 202includes corrugations 210. To install removable panel 200 in front panel144 of tote 140, rails 204 may be engaged in guides 212 in the sides offront opening 152. Removable panel 200 may be advanced downwardly onslots 212 until removable panels 200 bottom out on lower lip 214 offront panel 144 shown in FIG. 8. Pins 206 on the leading edge ofremovable panel 200 may engage in sockets 216 of front panel 144. At thesame time, posts 220 at the top of rails 204 may become flush with thetop of front panel 144. Latching tabs 208 of removable panel 200 maypass through slots 218 in front panel 144 of tote 140. Latching tabs 208may resiliently latch in slots 218.

A tote in a shelving system may have any shape and size. The dimensionsmay be based, for example, on the items to be stored in the totes. Inone embodiment, tote 140 is at least about 12 inches in depth. In oneembodiment, front opening 152 and back opening 154 are about 9.5 incheshigh, about 19.75 inches wide at the top of the opening, and about 17.75inches wide at the bottom of the opening.

System 100 includes bin label 230. Bin label 230 may be used as anidentifier for the system of totes. Each of totes 140 may include one oftote labels 232. Each of tote labels 232 may be used as an identifierfor the particular tote on which it is placed. In certain embodiments,multiple bin identifiers may be assigned to each tote in a system oftotes. In one embodiment, up to two bin identifiers can be assigned toeach tote. One of the assigned bin identifiers may be placed on one sideof a divider for the tote and the other assigned bin identifier can beplaced on the other side of the divider. The bin identifiers can bechanged manually if the location of the tote in the fulfillment centerchanges. In another embodiment, one of the assigned bin identifiers isplaced on one side of the tote and the other assigned bin identifier isplaced on another side of the tote (for example, the opposite side ofthe tote).

FIG. 10 illustrates one embodiment of a handle for a tote. Handle 150includes grip 242. Grip 242 includes concave edge 244. Concave edge 244may create an opening to allow handle 150 to be used when totes 140 arecoupled with one another (such as the opening shown between totes inFIG. 8).

In some embodiments, a tote system includes one or more dividers. Thedividers may subdivide the space in a tote into two or more segments.FIG. 11 illustrates an embodiment of a tote system including a divider.Tote system 260 includes tote 262 and divider 264. Divider 264 maycouple with tote 262 in receptacles 266. Pins 268 may engage in holescorresponding holes in tote 262. Divider 264 may create left and rightvolumes for holding items in totes 262. In some embodiments, latchingtabs on divider 264 may snap into slots in tote 262, similar to thatshown and described above for removable panels 200 relative to FIG. 9and FIG. 10. Engagement of latching tabs in the slots may serve toretain divider 264 in tote 262. In some embodiments, a tote isdimensioned so that a common part can be used as either a divider or aremovable wall. For example, both receptacles 266 and the front and rearopenings of tote 262 may receive divider 264. A system that allows aremoved wall to be installed as a divider may help keep removed wallsfrom being lost or separated from their respective totes.

In some embodiments, totes in a system are nestable such that one totecan be placed on top of another in a compact manner. Totes may benested, for example, when shelving systems are not needed for storingitems (for example, during non-holiday seasons).

In some embodiments, a tote includes stop elements. Stop elements maystop a tote being nested at a desired level. For example, stop elementsmay keep nested totes from becoming jammed together. FIG. 12 illustratesa tote including stop elements. Tote 140 includes nesting overload ribs270. Pads of a tote nested in tote 140 may bottom out on nestingoverload ribs 270.

FIG. 13 is a cross sectional view of two totes in a nested relationship.The upper one of totes 140 is bottomed out on nesting overload ribs 270of the lower one of the totes.

In some embodiments, totes are made to be selectively nested or stackedbased on the orientation of the totes relative to one another. Forexample, for totes 140 shown in FIG. 8, when totes 140 are placed one onanother such that sides 148A are aligned with one another and sides 148Bare aligned, totes 140 may nest, for example, in the manner shown inFIG. 13. By contrast, when totes 140 are placed one on another such thatsides 148A and side panels 148B alternate, totes 140 may stack, forexample, in the manner shown in FIG. 1.

In some embodiments, a dovetail connection may be a blind connection.FIGS. 14 and 15 are bottom views illustrating elements of a blinddovetail connection. Tote 280 includes blind dovetail socket 282 andreinforcing webs 284. Tote 286 includes tail 288 and reinforcing webs290. Tail 288 of tote 286 may couple in blind dovetail socket 282 oftote 280. Reinforcing webs 284 and 290 may reduce stress at the dovetailconnection.

In the embodiments shown in FIGS. 5, 14, and 15, totes are cross coupledby way of dovetail connections. Totes in a shelving system may, however,be cross coupled in various embodiments by any other couplingarrangement. Examples of coupling arrangements include pin-and-socket,snap-in connections, and hooks and grooves.

In some embodiments, a separate coupling device is used to coupleadjacent totes to one another. FIG. 16 illustrates a U-shaped couplerfor cross coupling totes. Totes 300 include rims 302. Rims 302 includethrough holes 304. Coupler 306 include cross bar 307 and pins 308, whichcombine to form a U-shape. Each of pins 308 of coupler 306 may passthrough one of through holes 304 in totes 302. Protrusions 310 of pins308 may catch on the underside of rims 302 of totes 300. Pins 308 maysnap into engagement on totes 300.

In certain embodiments, separate couplers are used to supplement, or inlieu of, integral coupling portions on totes. For example, as shown inFIGS. 3, 6, and 7, totes 140 include holes 167. Couplers may be insertedinto various combinations of holes 167 in adjacent totes to cross couplethe totes. For example, as shown in FIG. 7, coupler 169 may be used tocross couple adjacent totes 140.

In some embodiments, totes are cross coupled at an intersection of thecorners of a set of totes. FIG. 17 illustrates a device for crosscoupling four totes at a common intersection of the totes. Totes 320include holes 322. Coupling device 324 includes plate 326 and pins 328.One of pins 328 of coupling device 324 may be received into each ofholes 322 of totes 320. Coupling device 324 may couple all of totes 320to one another.

In some embodiments, totes in a stack may be coupled to inhibit verticalseparation of the upper and lower totes. Examples of couplingarrangement include snap-in elements on dedicated fasteners such asclips or screws. FIG. 18 illustrates one embodiment of a snap-inconnection between stacked totes. The lower of totes 340 includes pin342. The upper of totes 340 includes socket 344. Socket 344 includesslots 346. Protrusions 348 may snap into slots 346. Engagement of pins342 of the lower one of totes 340 in socket in the upper one of totes340 may inhibit separation of totes 340 when stacked. In someembodiments, a shelving system is coupled to inhibit separation invertical and horizontal directions. For example, a shelving system mayinclude horizontal cross coupling as described in FIG. 1 and verticalcross coupling as described in FIG. 18.

In some embodiments, the pin and socket relationship between totes maybe reversed from that shown in FIG. 18 such that the pin is on the upperone of the adjoining totes and the socket is on the lower one of theadjoining totes.

Although the totes described above relative to FIGS. 1-10 are depictedas having a rectangular footprint, totes for a shelving system may be,in various embodiments, any shape. Suitable shapes may include round,hexagonal, octagonal, triangular, or irregular. Different totes within ashelving system may be all the same size or different sizes.

In some embodiments, a tote system may include a pallet for supportingand/or transporting stacks of totes. In some embodiments, a singlepallet runs the entire width and depth of a shelving system (forexample, 16 feet wide by 3 feet deep). A pallet may include stiffeningelements (for example stiffening ribs) and/or mounting portions formoving the system (for example, for moving the system with a forklift orcrane.)

In some embodiments, a tote system includes a pallet with modularsections. Each modular section may support part of the totes in ashelving system. For example, in a shelving system that is 2 totes deepby 8 totes long, a pallet may include 4 pallet modular sections, each ofwhich supports a 2 by 2 stack of totes. The modular sections of thepallet may include coupling elements for connecting the modular sectionsto one another. For example, the modular sections of the pallet mayinclude dovetail elements similar to those in totes 140 described aboverelative to FIG. 2.

In certain embodiments, a pallet includes elements for aligning stacksof totes on the pallet. The alignment elements may be arranged tocorrespond to alignment elements on the totes. For example, a pallet fortotes 140 shown in FIG. 2 may include posts that correspond to alignmentsockets 194 and 196 described above relative to FIGS. 2, 3, 4, and 6. Incertain embodiments, a pallet may include elements for coupling thetotes on the pallet. In one embodiment, a pallet includes elements forsnapping totes in place on the pallet.

In some embodiments, a shelving system of totes includes lids. In someembodiments, lids are provided for totes in the uppermost tier of asystem. For example, a lid 123 may be provided on each of totes 102 intier 106C shown in FIG. 1. Lids may keep unwanted materials out of asystem. In some embodiments, lids on the top tier of totes in a systemkeep water (such as from building sprinkler system) from entering atotes in a system.

A tote for a shelving system, or portions thereof, may be produced byvarious manufacturing processes, including molding, casting, machining,extruding, forming, or cutting. In one embodiment, an air directingdevice is injection molded. Suitable materials for a tote may include apolymer or a metal. In certain embodiments, a tote is made of afire-retardant polymeric material. In some embodiments, a tote isproduced as a single part, such as by molding, forming, or machining. Inother embodiments, an air directing device is an assembly of two or moreparts.

In various embodiments, a shelving system including stacked totes isused for storing items in a materials handling facility. A materialshandling facility may include, for example, one or more facilities thatprocess, store, and/or distribute units of items including but notlimited to warehouses, distribution centers, hubs, fulfillment centers,nodes in a supply chain network, retail establishments, shippingfacilities, stock storage facilities, or any other facility configuredto process units of items.

In some embodiments, stacked totes are used to construct shelving tocreate or expand capacity for inventory. The capacity may be used, forexample, to quickly fulfill a temporary or transient need for additionalcapacity, such as during a holiday season. After the need for additionalcapacity has passed, the totes may be unstacked and removed from theirdeployed location. In one embodiment, a shelving system constructed fromtotes is used at a holiday fulfillment center. A holiday fulfillmentcenter may be in a warehouse, tent, pole barn, or any other suitablebuilding or location. After the holiday season is over, the totes may beremoved and the location vacated or re-configured for a differentpurpose.

FIG. 19 illustrates a logical representation or view of the operation ofone or more materials handling facilities that include one or moreinventory storage locations. Some or all of the inventory storagelocations may include shelving systems constructed from stacked totes,such as described above relative FIG. 1. In various embodiments, afulfillment network including multiple materials handling facilities(each of which may be configured in a manner similar to that ofmaterials handling facility 500) may be responsible for fulfillingmultiple orders, such as orders placed through an electronic commerce(“e-commerce”) portal, such as commerce portal component 110.

In various embodiments, a materials handling facility may include one ormore facilities that process, store, and/or distribute units of itemsincluding but not limited to warehouses, distribution centers, hubs,fulfillment centers, nodes in a supply chain network, retailestablishments, shipping facilities, stock storage facilities, or anyother facility configured to process units of items. For example, thisFIG. 19 may illustrate an order fulfillment center of a productdistributor, according to some embodiments.

Material handling facility 500 may include one or more inventory storagelocations 531 that each hold inventory 530. In one embodiment, some ofinventory storage locations 531 are permanent storage locations andothers of inventory storage locations are expansion locations, such atent or pole barn for a holiday fulfillment center. The expansionlocations may be outfitted with shelving systems constructed fromstacked totes, such as described above relative to FIGS. 1-10. Incertain embodiments, all of inventory storage locations 531 of amaterial handling facility 500 are constructed from stacked totes.

In some embodiments, a supplier ships inventory items (such as books andCDs) to inventory storage locations 531 with the items pre-loaded intotes. The supplier-loaded totes may be stacked at inventory storagelocations 531. In some embodiments, stacks of totes pre-loaded withinventory items are shipped (for example, on a pallet) to storagelocations 531.

Multiple customers 510 may submit orders to commerce portal component110 (which may be implemented on one or more network content servers112), where each order specifies one or more items from inventory 530 tobe shipped to the customer that submitted the order. The customer ordersmay be provided to order management component 118, which as describedabove may assign such orders to a materials handling facility (e.g., afulfillment center), as illustrated as orders 520. As described above,in various embodiments, the merchant may determine when a customerselects a substitute item for acquisition (e.g., after the customer isprovided with an order status message that recommends one or moreitems). In these cases, commerce portal component 110 may also provideorder management component 118 with substitute orders that specify anysubstitute items specified by the customer. The order managementcomponent may assign any of the above-described orders to a materialshandling facility in order to initiate fulfillment of the orders. In theillustrated embodiments, the orders assigned to materials handlingfacility 500 are illustrated as orders 520.

To fulfill the orders 520, the one or more items specified in each ordermay be retrieved, or picked, from inventory 530 (in the materialshandling facility, as indicated at 540. In some embodiments, the itemsare picked from lateral openings in stacked totes, such as the totesdescribed above relative to FIGS. 1-10.

Picked items may be delivered or conveyed, if necessary, to one or morestations in the materials handling facility for sorting 550 into theirrespective orders, packing 560, and finally shipping 570 to thecustomers 510. In various embodiments, picked items may be delivered toa station where individual units of items are associated with and placedinto particular conveyance receptacles, which are then inducted into aconveyance mechanism. The conveyance receptacles may then be routed toparticular destinations for the items contained within the receptaclesin accordance with the requests (orders) currently being processed, e.g.to sorting stations, under direction of a control system (e.g., controlsystem 502). A picked, packed and shipped order does not necessarilyinclude all of the items ordered by the customer; an outgoing shipmentto a customer may include only a subset of the ordered items availableto ship at one time from an inventory storage location.

A materials handling facility may also include a receiving 580 operationfor receiving shipments of stock (e.g., units of inventory items) fromone or more sources (e.g., vendors) and for moving or “stowing” thereceived stock into stock storage (e.g., inventory 530). In someembodiments, items are received in totes. In some embodiments, inventorystorage locations and/or shelving systems within existing inventorystorage locations are expanded to accommodate shipments of stock.

As described above, when incoming shipments are delayed or canceled bythe vendor, exceptions may occur for customer orders relying on suchitems. In various embodiments, the receiving 580 operation may alsoreceive and process returned purchased or rented items or orders fromcustomers. At least some of these items are typically returned toinventory 530.

The various operations of a materials handling facility may be locatedin one building or facility, or alternatively may be spread orsubdivided across two or more buildings or facilities. In variousinstances, it should be understood that references to elements, units,items, processes (or anything else) as being located within materialshandling facility 500 may easily be extended to encompass elements,units, items, processes (or anything else) proximate to but notphysically located within materials handling facility. For example,various elements, units, items, or processes (or anything else) may beimplemented outside of the materials handling facility, according tosome embodiments.

In various embodiments, shipments of one or more items at shipping 570may be transferred to one or more shipment carrier network(s) 575. Eachshipment carrier's network may include one or more distributionfacilities for storing items (e.g., hubs) as well as vehicles forconveying shipments (e.g., trucks) from such distribution facilitiesand/or materials handling facilities (such as materials handlingfacility 500) to various destinations (e.g., customer specifieddestinations).

In some embodiments, a method of storing items (for example, in theinventory of a merchant) includes holding items in stacked totes. FIG.20 illustrates one embodiment of holding items in stacked totes. At 500,items are provided in totes. Totes may be filled by a merchant, supplierfor the merchant, or another party.

At 502, at least some of the totes least two of the totes are crosscoupled with one another to form a base tier of totes. At 504, totes arestacked on the base tier totes to form at least one higher tier. Thetotes may be stacked such that the items in the totes are removablethrough lateral openings (for example, a front opening or a backopening) in the totes. In some embodiments, the totes are stacked at atemporary inventory storage location in response to identifying arequirement to expand a merchant's or distributor's inventory storage(for example, to handle increased orders during a holiday season).

At 506, the totes are transported from a first location to a secondlocation while at least some of the items are in the totes. The firstlocation may be, for example, a supplier facility or merchant materialhandling facility. Transportation may be by truck, semi trailer, air,rail, or any other shipment method. In one embodiment, stacked,cross-coupled totes with items are transported in a semi trailer.

The second location may be, for example, a holiday fulfillment center.At a fulfillment center, shelving system two totes deep by N totes wide(for example, 7 totes wide) may be placed on the floor of a room in thefulfillment center. In one embodiment, several shelving systems aredistributed at a fulfillment center. In one embodiment, each shelvingsystem is two totes deep with lateral access to the totes on both thefront and back of the system (for example, as shown in FIG. 1). In oneembodiment, 4-foot wide aisles are provided between each shelvingsystem.

In some embodiments, totes of a system are stacked and cross coupled toone another before being transported to the second location. In certainembodiments, pallets are used to transport the stacked and cross coupledtotes while the items are in the totes.

At 508, while the totes are stacked, items are removed from the totesthrough the lateral openings in the totes. Items may be removed, forexample, in response to receiving an order from a customer (for example,as described above relative to FIG. 19).

In certain embodiments, empty totes may be provided to a supplier ofitems to be stored. The supplier may load the totes with the items andship the items to retail merchant. The retail merchant may receive thetotes from the supplier and distribute the totes at a fulfillmentcenter.

In an embodiment, a method of making shelving for holding items includescross coupling and stacking totes such that items can be removed fromlateral openings in the totes. FIG. 21 illustrates one embodiment ofmaking a shelving system with stacked totes. At 520, two or more totesare cross coupled to form a base tier of totes. The totes may includelateral openings. In some embodiments, the shelving systems areconstructed at a temporary inventory storage location in response toidentifying a requirement to expand a merchant's or distributor'sinventory storage (for example, to handle increased orders during aholiday season).

At 522, totes are stacked on the base tier to form at least one highertier of totes. The totes may be stacked such that items can be placedinto the totes through the lateral openings. In some embodiments, lidsare placed on totes of the uppermost tier of a system.

At 524, items are placed into the totes. At 526, a customer order isreceived for one or more items in the totes (for example, as describedabove relative to FIG. 19). At 528, the item is identified and removedfrom the tote in response to the order.

Although the embodiments above have been described in considerabledetail, numerous variations and modifications will become apparent tothose skilled in the art once the above disclosure is fully appreciated.It is intended that the following claims be interpreted to embrace allsuch variations and modifications.

1-23. (canceled)
 24. A method of holding items, comprising: providingone or more items in each of two or more totes, at least one of thetotes comprising one or more lateral openings; laterally cross couplingat least two of the totes with one another to form a base tier of totes;and stacking one or more totes on at least one of the base tier totes toform at least one higher tier of totes, wherein the totes are stackedsuch that at least some of the items in the totes are removable throughat least one of the lateral openings.
 25. The method of claim 24,further comprising removing, while the totes are stacked, at least oneof the items from at least one of the totes through at least one lateralopening.
 26. The method of claim 24, further comprising transporting atleast a portion of the totes from a first location to a second locationwhile at least some of the items are in the totes.
 27. The method ofclaim 26, further comprising transporting at least a portion of thetotes from a first location to a second location while at least some ofthe items are in the totes and while the totes are stacked and crosscoupled to one another.
 28. The method of claim 27, wherein transportingat least a portion of the totes from a first location to a secondlocation while the totes are stacked and cross coupled comprises movingat least a portion of the stacked and cross-coupled totes on a pallet.29. The method of claim 24, wherein placing the one or more items ineach of two or more totes comprises: providing one or more empty totesto an item supplier; and receiving one or more items in at least one ofthe totes from the supplier.
 30. The method of claim 24, furthercomprising identifying a requirement for temporarily creating orexpanding inventory storage for a material handling facility, whereinthe stacking the one or more totes on the at least one of the base tiertotes expands inventory storage for the material handling facility. 31.A method of making a shelving system for storing items, comprising:cross coupling two or totes to form a base tier of totes, wherein atleast one of the totes comprises one or more lateral openings; andstacking one or more totes on at least one of the totes in the base tierto form at least one higher tier of totes, wherein the totes are stackedsuch items can be placed into the at least one of the totes through atleast one of the lateral openings.
 32. The method of claim 31, furthercomprising placing one or more items into at least one of the totesthrough at least one of the lateral openings.